Reactor and Product Optimization via Raman Fiber Optics Monitoring: Application to Polymer-Based Proppants

REY, CANDELA; ZUVIRÍA, GONZALO; RIVELLI, SOFÍA; GIANNETTI, ROCÍO; TOMBA, J. PABLO; CARELLA, JOSÉ M.

MACROMOLECULAR REACTION ENGINEERING

WILEY-V C H VERLAG GMBH

Año: 2021 vol. 15

1862-832X

A setup to characterize polymerization kinetics of polymer-based proppants produced in an industrial batch reactor by suspension polymerization is presented. A microscale reactor is designed to mimic temperature and pressure conditions of the industrial counterpart. Raman spectroscopy is used to follow the consumption of vinyl bonds of the styrene monomer and the crosslinker via disappearance of the peak at 1632 cm-1. Raman data from the microscale reactor are remotely obtained via a fiber optics system. Reaction progress by any generic formulation can be safely followed up to conversions of 90%, well beyond the gel point. Reaction rates are used to define feasible temperature?time profiles for the industrial reactor. In parallel, bulk and suspension polymerizations are carried out under those temperature?time profiles in a 3 L laboratory reactor to produce proppants formulations with the geometry required to perform product characterization, mainly focused on the thermal and mechanical response of the polymer particles. Overall, the whole setup allows optimization of proppant formulations and the cost of their processes of production.